Precision machining of Al2O3 ceramics using additively fabricated polyamide tool: wear and performance analysis under the effect of process kinematics

ABSTRACT Multiple process-induced factors in the free-abrasive precision machining often cause the tool surface to experience non-uniform wear, which deteriorates the quality of machining part. Accurate evaluations of the influencing factors are essential to improve the performance of the tool and understand the wear mechanism. This study examined the effect of kinematic coefficient K on the wear characteristics and performance of SLS-fabricated polyamide lapping tools during single-sided free abrasive precision machining of Al 2 O 3 ceramics. The kinematics contact interaction was modeled using a numerical framework, and key results analyzed, including the relative velocity, contact density, tangential velocity, and acceleration along the tool surface. Experimental investigations were carried out at the selected kinematic coefficients, and the tool active surface was quantified in terms parametric maximum height (Wt), surface topography, and cross-sectional area of the wear profile. The study applied a novel trapezoidal-based shell method to determine the wear volume, allowing evaluating the performance of the tool based on G-ratio. The ceramic samples showed a significant reduction in surface roughness from Sa 1.93 μm to 0.65 μm and 0.70 μm at K -2.5 and 2.5, respectively. Material removal was consistent, with 5.62 g and 5.52 g total removal, though the removal rate decreased overtime due to wear. Despite this, machining at K 2.5 achieved better G-ratio because of lower wear and relatively efficient material removal. Overall, the findings emphasize the potential of polyamide tools in free-abrasive precision machining of Al 2 O 3 ceramics and propose a novel approach for lapping tool wear volume analysis.